Laser-cut button veneer for a control device having a backlit keypad

ABSTRACT

A veneer configured to be secured to a backlit button of a control device may include a plate portion. The plate portion may have one or more laser-cut indicia defined therethrough, may have laser-cut rounded corners, and may have angularly offset outer edges that may be defined during an embossing process. The laser-cut indicia may be representative of a command for controlling an electrical load. The indicia may include an alphanumeric character, an icon, or the like, may define one or more substantially zero-radius corners, and may define respective inner surfaces that are substantially perpendicular to an outer surface of the plate portion. A laser-cut alphanumeric character may have variable (e.g., continuously variable) line width. The plate portion may define a rib that suspends a floating portion of the alphanumeric character relative to an open portion. The rib may define a thickness that does not exceed 0.003 inches.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional patent applicationNo. 62/207,767, filed Aug. 20, 2015, and to U.S. provisional patentapplication No. 62/269,498, filed Dec. 18, 2015, both of which areincorporated herein by reference in their respective entireties.

BACKGROUND

Load control devices may be used to control the amount of powerdelivered from a power source, such as an alternating-current (AC) powersource, to one or more electrical loads. An example of such a loadcontrol device is a wall-mounted dimmer switch. Load control devices maybe integrated into home automation systems.

Home automation systems, which have become increasing popular, may beused by homeowners to integrate and/or control multiple electricaland/or electronic devices in their homes. For example, a homeowner mayconnect devices such as appliances, lights, blinds, thermostats, cableor satellite boxes, security systems, telecommunication systems, and thelike to each other via a wireless network.

The homeowner may control such devices using a central (e.g., automated)controller, a dedicated remote control device (e.g., a wall-mountedkeypad), a user interface provided via a phone, tablet, computer, orother device that is directly connected to a home network or remotelyconnected via the Internet, and so on. These devices may communicatewith each other and/or with a control device, for example to improveefficiency, convenience, and/or usability of the devices.

Dedicated remote control devices, such as wall-mounted keypads, may bemanufactured to be aesthetically pleasing. For example, wall-mountedkeypads may include faceplates and buttons made of metal, glass, orother materials to lend the keypads a luxury aesthetic when compared totraditional plastic keypads. However, the manufacture of such keypadsmay be problematic. For instance, in the case of metallic buttons,indicia are typically formed in the buttons using machining processes.However, such machining processes have limitations. For instance, smallscale machining processes may be incapable of very fine detail, whichmay lead to undesirable aesthetics in the indicia, and/or may introduceinaccuracies or inconsistencies into the manufacturing process thatreduce yield. Additionally, such machining processes are typically timeintensive, which may impact manufacturing costs and capacity.

SUMMARY

As described herein, a veneer may be configured to be secured to abacklit button of a control device, such as a wall-mounted keypad. Thecontrol device may be configured for use with a load control device,such as a dimmer switch.

The veneer may include a plate portion that has one or more laser-cutindicia defined therethrough. The plate portion may further includelaser-cut rounded corners. The veneer may further include a fillermaterial that is disposed in the one or more indicia.

The laser-cut indicia may be representative of a command for controllingan electrical load. The indicia may include an alphanumeric character,an icon, or the like. The indicia may define a substantially zero-radiuscorner. The indicia may define respective inner surfaces that aresubstantially perpendicular to an outer surface of the plate portion ofthe veneer.

At least a section of a laser-cut alphanumeric character may define avariable (e.g., continuously variable) line width. If the alphanumericcharacter includes a floating portion, such as the letter “o” forexample, the plate portion of the veneer may define one or more ribsthat suspend the floating portion relative to an open portion of thealphanumeric character. Each rib may define a thickness that does notexceed 0.003 inches, for instance such that the ribs are virtuallyinvisible to the naked eye of a user of the control device.

An example method of producing a button that is configured forinstallation in a control device having a backlit keypad may includelaser cutting one or more indicia into a veneer that is configured to beattached to an outer surface of the button. The indicia may berepresentative of a command for controlling an electrical load. Themethod may include adhering the veneer to the outer surface of thebutton.

Another example method of producing a button that is configured forinstallation in a control device having a backlit keypad may includeembossing a metal blank with an array of button veneers. The method mayinclude laser cutting one or more indicia into at least one of thebutton veneers. The indicia may be representative of a command forcontrolling an electrical load. The method may include disposing afiller material into the indicia. The method may include separating theveneers from the blank. For example, the method may include lasercutting slots along respective perimeters of the button veneers. Theslots may enable separating the veneers from the blank. Laser cuttingthe slots may include rounding the corners of each of the veneers. Themethod may include securing each veneer to a corresponding button of thekeypad.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example control device, configured asa wall-mounted keypad, for use in a load control system for controllingthe amount of power delivered to one or more electrical loads.

FIG. 2 is a perspective view of an example button that may beimplemented in a control device, the button including a button body anda veneer with laser-cut indicia that is attached to the button body.

FIG. 3 depicts an example indicia that may be laser cut into a veneersecured to the button of a control device.

FIG. 4 depicts an example process for producing a button for use in acontrol device, the button including a veneer having one or morelaser-cut indicia.

FIG. 5 is a perspective view of a metal blank, stamped to form an arrayof control device button veneers.

FIG. 6 is a perspective view of the metal blank illustrated in FIG. 5,after a laser cutting process has been performed on the blank.

FIG. 7 is a zoomed-in view of a portion of the metal blank illustratedin FIG. 6, illustrating a laser-cut tab that suspends a veneer relativeto the blank.

FIG. 8A depicts the button of a control device, and a laser-cut buttonveneer, before the veneer is secured to the button.

FIG. 8B depicts the button illustrated in FIG. 8A, with the veneersecured to the button.

FIG. 9 is a perspective view of another example control device,configured as a wall-mounted keypad, for use in a load control systemfor controlling the amount of power delivered to one or more electricalloads.

DETAILED DESCRIPTION

FIG. 1 depicts an example control device that may be configured for usein a load control system for controlling one or more load controldevices and/or electrical loads, such as lighting loads, motorizedwindow treatments, or the like. As shown, the example control device isconfigured as a wall-mounted keypad 100. The keypad 100 may include afaceplate 102, one or more buttons 110, and a housing 120 that isconfigured to be mounted to a structure, such as an interior wall of abuilding. The illustrated keypad 100 may be configured to control a loadcontrol device, such as a load control device configured to control anamount of power delivered to one or more electrical loads (e.g., one ormore lighting loads) from a power source, such as an alternating-current(AC) power source or a direct current (DC) power source.

The faceplate 102 may define an opening 104 that extends therethroughand that is configured to at least partially receive the buttons 110.For example, in accordance with the illustrated keypad 100, the opening104 may be sized to receive the buttons 110 such that a gap 106 isdefined between inner edges of the opening 104 and corresponding outerperipheral surfaces of the buttons 110. The keypad 100 may be configuredsuch that the gap 106 remains uniform around the perimeter of theopening 104. The keypad 100 may further be configured such that facingedges of adjacent buttons 110 are spaced apart from each other by a gap108 that is substantially the same as (e.g., equal to) the gap 106between the buttons 110 and the opening 104 of the faceplate 102. Thefaceplate 102 may be made of the same material, or using the same mix ofmaterials, as the buttons 110. Alternatively, the faceplate 102 and thebuttons 110 may be made of different materials. In accordance with anexample implementation, the buttons 110 may be made of plastic and mayhave metal veneers that are attached thereto, and the faceplate 102 maybe made of the same metal as the button veneers. The faceplate 102 maybe configured to be attached to (e.g., removably attached to) thehousing 120.

The illustrated keypad 100 includes four buttons 110 that arerectangular in shape and are of the same size. However, it should beappreciated that the keypad 100 is not limited to buttons having theillustrated button geometries. For example, the keypad 100 mayalternatively include more or fewer buttons having the same or differentgeometries and/or sizes. The buttons 110 may be made of a mix ofmaterials. For example, each illustrated button 110 may include a buttonbody that is made of a first material (e.g., plastic), and may include aveneer 130 that is made of a different material (e.g., metal) and thatis attached to the button body of the button 110.

Each veneer 130 may have one or more indicia 140 formed therein, such ascut therethrough. The indicia 140 may be representative of a functionthat the keypad 100 is configured to execute or that the keypad isconfigured to cause to be executed. For example, the indicia 140 may berepresentative of a command for controlling an electrical load. Inaccordance with an example implementation of the keypad 100, the indicia140 may be representative of a message that the keypad 100 is configuredto transmit, for instance a message that includes a command forexecution by a load control device that is associated with the keypad100. In accordance with an alternative example implementation, thekeypad 100 may include an integral load control circuit (e.g., a dimmingcircuit), and the command may cause the integral load control circuit tocontrol an electrical load that is electrically connected thereto. Theindicia 140 of a particular button 110 may include one or more visualrepresentations of a function associated the button 110, such as, forexample, one or more alphanumeric characters, icons, etc. in anycombination.

In accordance with the buttons 110 of the illustrated keypad 100, theindicia 140 may be words that are indicative of respective functionsthat are invoked by depressing the buttons 110. The indicia 140 may belaser cut through the veneers 130 of the buttons 110, or may otherwisebe formed on the buttons 110. The keypad 100 may include one or morelighting elements (not shown) that are configured to illuminaterespective interiors of the buttons 110, such that the indicia 140 arebacklit from within an interior of the keypad 100. For example, thekeypad 100 may include a plurality of lighting elements, such as lightemitting diodes (LEDs), that are disposed within the housing 120 of thekeypad 100, behind the buttons 110, and that are configured to backlightthe buttons 110. In this regard, the illustrated keypad 100 may bereferred to as a backlit keypad or control device.

Examples of button indicia and button backlighting systems are describedin greater detail in commonly-assigned U.S. Provisional PatentApplication No. 62/048,652, titled “Control Device Having Buttons WithMetallic Surfaces And Backlit Indicia,” and U.S. Provisional PatentApplication No. 62/048,658, titled “Control Device Having Buttons WithMultiple-Level Backlighting,” the entire disclosures of which areincorporated herein by reference.

The keypad 100 may be configured to transmit one or more digitalmessages to one or more external load control devices (e.g., dimmerswitches) and/or electrical loads via a communication link, for examplein response to one or more buttons 110 being depressed. The one or moredigital messages may include, for example, one or more commands forexecution by the one or more external load control devices to controlrespective electrical loads (e.g., lighting loads). The communicationlink may comprise a wired communication link or a wireless communicationlink, such as a radio-frequency (RF) communication link. In accordancewith an alternative configuration, the keypad 100 may further include aninternal load control circuit (not shown) for controlling the powerdelivered to one or more electrical loads (e.g., lighting loads).Examples of load control systems having remote control devices, such asthe keypad 100, are described in greater detail in commonly-assignedU.S. Provisional Patent Application No. 62/150,227, titled “ControlDevices Having Independently Suspended Buttons For ControlledActuation,” U.S. Pat. No. 6,803,728, issued Oct. 12, 2004, entitled“System For Control Of Devices,” and U.S. Patent Application PublicationNo. 2014/0001977, published Jan. 2, 2014, entitled “Load Control SystemHaving Independently-Controlled Units Responsive To A BroadcastController,” the entire disclosures of which are incorporated herein byreference.

FIG. 2 depicts an example button 210 that may be a component of acontrol device. For example, the button 210 may be implemented as one ormore of the buttons 110 of the keypad 100. As shown, the button 210includes a button body 220 and a veneer 230 that is attached to a frontsurface of the button body 220. The button body 220 may be referred toas a as a carrier portion, such as a carrier portion of the button 210or more generally as a carrier portion of a control device in which thebutton 210 is installed, such as the keypad 100.

The veneer 230 may include a plate portion 232 and may define peripheralwalls 234 that extend rearward from the plate portion 232. The plateportion 232 may define a front surface 233 of the veneer 230. As shown,the plate portion 232 may define a flat, substantially planar frontsurface 233. The plate portion 232 and the peripheral walls 234 maydefine four corners 231 of the veneer 230. The veneer 230 may defineouter edges 236 that extend along an outer perimeter of the plateportion 232, between the corners 231, along an interface between theplate portion 232 and the peripheral walls 234. As shown, the outeredges 236 of the veneer 230 may be angularly offset relative to thefront surface 233. However, it should be appreciated that the veneer 230is not limited to the illustrated outer edges 236. For example, theveneer 230 may be alternatively formed, with outer edges 236 that may berounded, may be square, or may define other geometries relative to thefront surface 233.

In an example implementation, the veneer 230 may be formed from a sheetof metal, for example by an embossing process, a progressive stampingprocess, or the like. The formation process of the veneer 230 maydefine, for example, one or more of the plate portion 232, theperipheral walls 234, and the outer edges 236. The corners 231 of theveneer 230 may be rounded, for example during a laser cutting processthat separates the formed veneer 230 from a blank after the formingprocess is performed.

The button body 220 may be configured such that the plate portion 232and the peripheral walls 234 of the veneer 230 at least partiallyenclose a front portion of the button body 220 when the veneer 230 isattached to the button body 220. The button body 220 may be made of anysuitable material, such as plastic.

The veneer 230 may include one or more indicia, such as indicia 240 thatare defined in the plate portion 232 of the veneer 230. For example, theindicia 240 may be formed during a laser cutting process. As shown, theindicia 240 extend into the front surface 233 of the veneer 230 andthrough the plate portion 232. The front surface 233 of the veneer 230may alternatively be referred to as an outer surface of the veneer 230.The veneer 230 may be made of any suitable material, such as metal. Thebutton body 220 may be made of a translucent material, for instancewhite or clear plastic, such that when the button body 220 is backlit,light may pass through the button body 220 and reach an inner surface ofthe veneer 230, for example an inner surface of the plate portion 232.Such light may be emitted, for example, from the interior of a controldevice in which the button 210 is installed, such as the keypad 100. Inaccordance with such an implementation, the indicia 240 of the veneer230 may expose corresponding underlying surfaces of the button body 220,such that the indicia 240 may be illuminated when the button body 220 isbacklit. In this regard, the veneer 230 may be configured to be securedto a backlit button of a control device.

The illustrated indicia 240 include letters that form a word. However,the indicia 240 are not limited to letters, and may include anycombination of alphanumeric characters, icons (e.g., symbols), or thelike. The indicia 240 may be representative of a command for controllingan electrical load. For example, the indicia 240 may be representativeof: a command message that may be transmitted by a control device inwhich the button 210 is operatively installed; of a command that isexecuted internally by such a control device; of a result of theperformance of a command; or the like. To illustrate, one or morecommand messages may be transmitted by such a control device in responseto one or more actuations of the button 210. The veneer 230 may includea filler material (not shown) that is disposed into the indicia 240. Thefiller material may prevent the accumulation of debris (e.g., dirt,skin, or the like) in the indicia 240. The filler material may, forexample, be backfilled into the indicia 240 such that the fillermaterial is coplanar with the front surface 233 of the veneer 230. Thefiller material may further function to improve the optical performanceof the indicia 240 when one or more of the buttons 210 are backlit, forinstance to improve the readability of the indicia 240 when viewed fromoff angle.

Forming the indicia 240 of the veneer 230 via a laser cutting processmay enable the indicia 240 to exhibit one or more characteristics thatare not typically achievable in indicia defined via known processes ofbutton veneer manufacture, such as machining. Examples of suchcharacteristics are illustrated in FIGS. 2 and 3.

For example, as shown in FIG. 2, in accordance with a characteristic oflaser-cut indicia 240, the indicia 240 have corresponding inner surfaces242 that may be substantially perpendicular to the front surface 233 ofthe veneer 230, for example approximately 89°−91° from the frontsurface. This is in contrast to indicia formed by known techniques ofmachining into material having a planar surface, which indicia mayexhibit tapered inner surfaces that are not perpendicular with respectto the planar surface. Perpendicular inner surfaces, such as innersurfaces 242, may enable more light to be emitted from the indicia 240,which may improve the aesthetic characteristics of the indicia 240, andthus of the button 210, for instance when the button 210 is backlit.

FIG. 3 depicts a portion of the example indicia 240, in particular theletter “R.” As shown, the plate portion 232, once laser cut with theindicia 240, defines one or more open portions 235 that extend throughthe plate portion 232, and may define one or more floating portions 237,such as that defined by the hoop of the “R.” The open portions 235 andfloating portions 237 may be referred to as being defined by thecorresponding indicia 240.

In accordance with another characteristic of laser-cut indicia 240, theindicia 240 may define one or more corners 244 that have very smallminimum radii. For example, the corners 244 of the illustrated “R” ofthe indicia 240 may have a minimum radius of approximately 0.0004 inchesor smaller. The corners 244 may be referred to as inside corners of theindicia 240. The corners 244 may appear, for instance to the naked eyeof a user of a control device in which the button 210 is installed, assharp corners having no radii at all. In this regard, the corners 244 ofthe illustrated indicia may be referred to as substantially zero-radiuscorners, or more generally as zero-radius corners. In contrast, thecorners of indicia (e.g., alphanumeric characters) that may be formedusing known machining techniques may have minimum radii of approximately0.0035″. The presence of substantially zero-radius corners, such as thecorners 244 of the illustrated indicia 240, may enhance the aestheticcharacteristics of the indicia 240, and thus of the button 210, forinstance when the button 210 is backlit.

The plate portion 232 may further define one or more ribs 238 thatsuspend one or more corresponding floating portions 237 relative to oneor more open portions 235. For example, in accordance with theillustrated “R,” the plate portion 232 defines three ribs 238 thatsuspend the floating portion 237 relative to the three open portions235. The ribs 238 within a portion of an indicia 240, for instancewithin a particular alphanumeric character, may be configured to enablethe control of one or more aspects of the separation of one or morescrap pieces (not shown) from the plate portion 232 during the lasercutting process. The one or more scrap pieces may correspond, forexample, to the open portions 235 of the indicia 240. Such aspects mayinclude, for example, how one or more scrap pieces release from theplate portion 232 (e.g., twisting, bending, and the like) and/or whenone or more scrap pieces release from plate portion 232 during the lasercutting process. One or both of the number of ribs 238 that are definedby an indicia 240 and the corresponding locations of the ribs 238 mayinfluence the aspects of scrap piece separation. Control of theseparation of scrap pieces from the plate portion 232 may assist withsuccessful completion of the process of laser cutting the indicia 240.In this regard, an indicia 240 (e.g., a font) may be designed to enhanceperformance of laser cutting the indicia 240 into the plate portion 232of a veneer 230.

In accordance with still another characteristic of laser-cut indicia240, the laser-cutting process may be performed such that the ribs 238are thinner than the thickness of ribs achievable with known machiningprocesses. For example, the illustrated ribs 238 may be defined with athickness TH1 that may be, for example, between 0.002 inches and 0.004inches, such as about 0.003 inches. In this regard, the ribs 238 maydefine respective thicknesses that do not exceed 0.003 inches. At athickness of approximately 0.003 inches or narrower, the ribs 238 may bevirtually invisible to the naked eye of a user of the keypad 100. Itshould be appreciated that rib thickness narrower than 0.002 inches maybe achievable with laser cutting. It should further be appreciated thatthe ribs 238 of a particular portion of the indicia 240, such as theletter “R,” may have the same thickness (e.g., TH1). Alternatively, oneor more of the ribs 238 may have different thicknesses. Reducing thethickness of the ribs 238 may cause the ribs 238 to be less visible, forexample by a user of a control device in which the button is installed210. Such ribs 238 may improve the aesthetic characteristics of theindicia 240, and thus of the button 210, for instance when the button210 is backlit.

By contrast, to achieve rib thicknesses similar to those of theillustrated ribs 238 via machining processes may be undesirably timeconsuming, and may be accompanied by high failure rates which may inturn reduce manufacturing yield. Additionally, the illustrated ribs 238may be formed with substantially zero-radius corners 244, while ribscreated via machining or via other processes, such as chemical photoetching, electrical discharge machining, or the like, may exhibitrounded corners that are visible to the naked eye and/or that may beaesthetically degraded by one or more heat affected zones.

In accordance with still another characteristic of laser-cut indicia240, such an alphanumeric character may exhibit variable (e.g.,continuously variable) line width. For example, a first section of theillustrated portion of the indicia 240 may exhibit a first line widthLW1. A second section of the portion of the indicia 240 may exhibit asecond line width LW2 that is narrower than the first line width LW1,and a third section of the portion of the indicia 240 may exhibit athird line width LW3 that is wider than the first line width LW1 and thesecond line width LW3. Such continuously varying line widths aretypically difficult to implement using known machining techniques, forinstance requiring multiple machining passes, z-axis translation duringmachining pass, or the like. The presence of varying line width, such asthat exhibited by the “R” of the illustrated indicia 240, may enhancethe aesthetic characteristics of the indicia 240, and thus of the button210, for instance when the button 210 is backlit.

It should be appreciated that respective portions of a laser-cutindicia, such as the example indicia 240, may exhibit one or more of theabove-described characteristics, such as all of the above-describedcharacteristics, in any combination.

FIG. 4 depicts an example process 400 for producing a button 510 (e.g.,as shown in FIGS. 5-7B) for use in a control device. For example, thebutton 510 may be implemented as one or more of the buttons 110 of thekeypad 100. At 402, a formation process may be performed on a blank 500to define one or more button veneers 530, as shown in FIG. 5. The blank500 may be, for example, a sheet of metal. As shown, the blank 500 maybe a rectangular sheet of stainless steel. The blank 500 may define aplanar front surface 502 and an opposed rear surface 504, and may beflat prior to the embossing process. The formation process may be, forexample, a sheet metal embossing process, a progressive stampingprocess, or another process. In accordance with the illustrated process400, the veneers 530 may be formed by embossing the veneers 530 into theblank 500.

During the embossing process, each of the one or more veneers 530 may bedefined by forming a plate portion 532 and peripheral walls 534 thatextend around a perimeter of each veneer 530 into the blank 500. Theplate portions 532 may define respective front surfaces 533 of theveneers 530. As shown, the plate portion 532 may define respective flat,substantially planar front surfaces 533. The plate portion 532 and theperipheral walls 534 of each veneer 530 may define four corners 531 ofthe veneer 530. Each veneer 530 may define outer edges 536 that extendalong an outer perimeter of the plate portion 532, between the corners531, along an interface between the plate portion 532 and the peripheralwalls 434. As shown, the outer edges 536 of each veneer 530 may beangularly offset relative to the front surface 533. However, it shouldbe appreciated that the veneers 530 are not limited to the illustratedouter edges 536. For example, the veneers 530 may be alternativelyformed, with outer edges 536 that may be rounded, may be square, or maydefine other geometries relative to the front surfaces 533.

As shown, the veneers 530 may be embossed into the rear surface 504 ofthe blank 500, such that the plate portions 532 of the veneers 530 maybe spaced from the front surface 502 of the blank 500. In accordancewith the example process 400, the plate portion 532 of each veneer 530may be spaced from the front surface 502 of the blank by approximately0.01 inches. The illustrated blank 500 is embossed to define a verticalarray of four veneers 530. However, it should be appreciated that moreor fewer veneers 530 may be embossed, and that the veneers 530 may beembossed in any alignment relative to each other.

Optionally, during the embossing process, one or more alignment featuresmay be defined in the blank 500. The alignment features may be used toregister the blank 500 in position relative to respective machinesduring one or more portions of the process 400. For example, as shown,the blank 500 may be embossed with a plurality of alignment featuresthat include apertures 506 and 508 that may be spaced from the veneers530. The apertures 506 and 508 may be configured as optical alignmentfiducials, for example. To illustrate, the blank 500 may be positionedwithin a laser cutting apparatus, via the apertures 506 and 508, priorto performing the laser cutting process.

At 404, a surface finish may be applied to the embossed blank 500. Thesurface finish may be applied, for example, to one or both of the frontsurface 502 of the blank 500 and the rear surface 504 of the blank 500.In this regard, one or both of a front surface 533 and a rear surface535 of each veneer 530 may be treated. The front surface 533 of eachveneer 530 may be referred to as an outward-facing surface, and the rearsurface 535 of each veneer 530 may be referred to as inward-facingsurface.

One or more laser cutting processes may be performed on the blank 500.For example, at 406, a laser cutting apparatus may be configured toperform a first laser cutting process to define indicia 540 in one ormore of the veneers 530. As shown, respective indicia 540 may be lasercut through the plate portion 532 of each of the veneers 530. That is,the indicia 540 may be defined into the front surface 533, and throughthe rear surface 535, of the plate portion 532 of each veneer 530. Theillustrated indicia 540 include letters that form words. However, theindicia 540 are not limited to letters, and may include any combinationof alphanumeric characters, icons (e.g., symbols), or the like. Theindicia 540 may be representative of a command for controlling anelectrical load. For example, the indicia 540 may be representative of:a command message that may be transmitted by a control device in whichthe button 510 is operatively installed; of a command that is executedinternally by such a control device; of a result of the performance of acommand; or the like.

At 408, during a second laser cutting process, the veneers 530 may bepartially cut out from the blank 500. For example, one or more slots 507may be laser cut through the blank 500 (e.g., into the front surface 502and through the rear surface 504) along the respective perimeter of eachveneer 530. In this regard, respective outer dimensions of the plateportions 532 of the veneers 530 may be defined by the second lasercutting process 408. The laser cutting apparatus may be configured toround the corners 531 of the veneer 530, for example while cutting theslots 507. For example, the corners 531 of the illustrated veneers 530may be rounded with a radius of approximately 0.005 inches during thelaser-cutting process.

To cut the slots 507, the laser cutting apparatus may be configured toadjust the focal point of the laser from a first z-axis position whereinthe focal point of the laser is positioned relative to the frontsurfaces 533 of the veneers 530, to a second, lower z-axis positionwherein the focal point of the laser is positioned relative to the frontsurface 502 of the blank 500. In this regard, the laser apparatus may beconfigured to adjust the focal point of the laser along a verticaldirection relative to the blank 500 during the laser cutting process.

During performance of the second laser cutting process 408, one or moreportions of material of the blank 500 within the slots 507 may be leftin place, to suspend each veneer 530 relative to the blank 500. Forexample, as shown, the slots 507 around each veneer 530 may be definedsuch that four tabs 509 remain that retain the veneer 530 in positionrelative to the blank 500 (e.g., as shown in FIG. 7). The illustratedtabs 509 are approximately 60 microns wide (relative to opposed sides ofthe blank 500) and are approximately 20 microns high (relative toopposed upper and lower ends of the blank 500). It should beappreciated, however, that the tabs 509 are not limited to theillustrated arrangement (e.g., number and respective locations of thetabs 509) or the illustrated tab dimensions.

It should be appreciated that the first laser cutting process at 406 andthe second laser cutting process at 408 may be performed discretely fromeach other. Alternatively, the first and second laser cutting processes406, 408 may be performed as portions of a single laser cutting process(e.g., combining 406 and 408) that is performed on the blank 500. At theconclusion of the laser cutting process and/or processes, the veneers530 may be suspended relative to the blank 500 via the tabs 509. In thisregard, the blank 500, including the veneers 530, may be removed fromthe laser cutting apparatus as a single piece.

At 410, a filler material (not shown) may be disposed into the indicia540 of the respective veneers 530. The filler material may at leastpartially fill the indicia 540. For example, the filler material mayfill the indicia 540 such that the filler material defines a fillersurface that may be subsurface or convex relative to the front surfaces533 of veneers 530. In such an example, the filler surface may defineone or more fillets along edges of the inner surfaces of the indicia540, which may reduce the effective depth of the indicia 540.Alternatively, the filler material may fill the indicia 540 such that atleast a portion of a filler surface defined by the filler material issubstantially flush with (e.g., coplanar with) the front surfaces 533 ofveneers 530. The filler material may function to reduce the generationof debris (e.g., dirt, skin, or the like) in the indicia 540, forexample by reducing (e.g., eliminating) one or more abrasive edgesdefined by the indicia 540 that may, for example, scrape material fromthe finger of a user pressing the button 510 to which the veneer 530 isattached. The filler material may function to prevent the accumulationof such debris in the indicia 540. The filler material may furtherfunction to improve the optical performance of the indicia 540 when oneor more of the buttons 510 are backlit, for instance to improve thereadability of the indicia 540 when viewed from off angle.

The filler material may be any suitable material, such as a laminatingfilm that, upon being heated, may flow and/or be mechanically disposed(e.g., pressed) into the indicia 540 of the veneers 530. In an example,a commercial laminating film may be used. The laminating film may, forexample, include a first layer comprising polyester base material and asecond layer comprising ethylene-vinyl acetate (EVA) adhesive. It shouldbe appreciated that the constitution (e.g., material and layers) of thelaminating film is not limited to the example described herein. Nor isthe filler material limited to laminating film. For example, the fillermaterial may comprise any other material that may flow to fill theindicia 540 of the veneers 530 and/or bond to corresponding surfaces ofthe veneers 530, such as the inner surfaces of the indicia 540 or therear surfaces 535 of the veneers 530.

A portion of laminating film may be pre-configured to define a fillerblank for use in an example process for filling the indicia 540 of oneor more veneers 530. For example, a sheet of laminating film may be cutsuch that a number of tabs are defined that correspond to respectiveveneers 530. In accordance with an example process for filling theindicia 540 of the veneers 530 of the blank 500 (e.g., as shown in FIG.6), a portion of laminating film may be cut to define a filler blankthat includes a support strip and four tabs that extend outward from thesupport strip and that are spaced apart from each other along a lengthof the support strip. In accordance with an example filler blank, eachtab may be sized to cover an area of the plate portion 532 of acorresponding one of the veneers 530, for instance where indicia 540 maybe defined in the veneer 530.

The filler blank may define one or more alignment features that mayallow the filler blank to be properly located during an example indiciafilling process. For example, the support strip of the filler blank maydefine one or more apertures that extend therethrough, the aperturesconfigured to receive complementary alignment features (e.g., posts) ofa laminating apparatus, such that the filler blank is properly orientedrelative to the blank 500, and such that each tab is properly orientedrelative to a corresponding one of the veneers 530. One or more portionsof the filler blank, such as the support strip, may be configured (e.g.,shaped) to ease removal of one or more remaining portions of the fillerblank at the conclusion of an indicia filling process, and such thatremoval may be achieved without degrading properties of the laminatingfilm, such as adhesion to the indicia 540 and/or veneers 530, or athickness of the laminating film.

An example process for filling the indicia 540 of one or more veneers530 using a laminating film filler blank may include the use of one ormore portions of adhesive release material. The adhesive releasematerial may be any material that, during heating of the laminatingfilm, may not adhere to and/or modify surfaces of the veneers 530 and/orthe blank 500 to which adhesion of the laminating film is not desired.In accordance with an example process for filling the indicia 540 of oneor more veneers 530 using a laminating film, the adhesive releasematerial may be paper or another material suitable to prevent thelaminating film from bonding to the veneers 530 during an indiciafilling process. The adhesive release material may be configured (e.g.,cut) to mask areas of the blank 500, such as the veneers 530, to whichadhesion of the laminating film is not desired. In an example, theadhesive release material may define a shape that is substantially thesame as that of the support strip of the filler blank.

The adhesive release material may define one or more alignment featuresthat may allow the adhesive release material to be properly locatedduring an example indicia filling process. For example, the adhesiverelease material may define one or more apertures that extendtherethrough, the apertures configured to receive complementaryalignment features (e.g., posts) of a laminating apparatus. Therespective apertures may be defined to align with one or more aperturesdefined by the filler blank, such that the adhesive release material maybe properly oriented relative to the filler blank and the blank 500. Theadhesive release material may be configured (e.g., shaped) to easeremoval of one or more remaining portions of the filler blank at theconclusion of an indicia filling process. The adhesive release materialmay be configured to exhibit one or more properties, such as materialthickness, that may enable the adhesive release material to promote aconsistent finished lamination thickness within the filled indicia 540of a veneer 530.

A laminating apparatus may be provided in an implementation of anexample indicia filling process. An example laminating apparatus may,for example, comprise a laminating press that includes a locating nestand a pressure plate. The laminating apparatus may be configured toapply one or both of heat and pressure to material (e.g., directly orindirectly) that is disposed between the pressure plate and the locatingnest, such as the laminating film, at particular times during an exampleindicia filling process.

The locating nest and pressure plate may be configured to cooperate toapply compression forces to material that is disposed therebetween. Forexample, the laminating apparatus may be configured such that one orboth of the pressure plate and the locating nest move toward each otherduring an example indicia filling process. For example, the pressureplate and the locating nest may both be configured to move toward oneanother during an example indicia filling process, or alternatively oneof the pressure plate or the locating nest may be fixed relative to theother during the indicia filling process. The laminating apparatus maybe configured to evenly distribute compressive force to the laminatingfilm (e.g., via the locating nest and/or via the pressure plate) duringan example indicia filling process, for example in accordance with aparticular time sequence and/or duration of the process.

The laminating apparatus may be configured to generate and apply heat tomaterial that is disposed between the pressure plate and the locatingnest. For example, one or both of the locating nest and the pressureplate may be configured to generate and evenly distribute heat to thelaminating film throughout a controlled range of temperatures during anindicia filling process. In an example, the laminating apparatus maygenerate heat across a controlled range of temperatures in accordancewith a particular time sequence and/or duration of the process. Thelaminating apparatus may be configured to transfer heat to thelaminating film (e.g., directly or indirectly) from the locating nest,from the pressure plate, or from a combination of the locating next andthe pressure plate. The laminating apparatus may be configured togenerate repeatable temperature and/or heat distribution overconsecutive cycles of an example indicia filling process.

In accordance with an example implementation of a laminating apparatus,the locating nest may include a substantially plate-shaped body thatdefines a rectangular outer perimeter and an upward-facing innersurface. The body may define a recess that extends into the innersurface. The locating nest may include a resiliently deformable pad thatis configured to be received in the recess. The pad may be sized suchthat when a blank 500 is positioned on the pad during an example indiciafilling process, the outer perimeter of the blank 500 does not extendbeyond corresponding sides of the pad. For example, the pad may define arectangular shape, and may be elongate between first and second endssuch that the pad defines a length that is longer than a height of theblank 500, and may define first and second sides that are spaced apartfrom each other by a distance that is substantially equal to a width ofthe blank 500.

The pad may be configured to promote conformance of the laminating filminto the respective indicia 540 of one or more veneers 530 during anindicia filling process. For example, during an example indicia fillingprocess, the filler blank may be compressed between a blank 500 and thepad. The pad may deform resiliently under compressive forces generatedby the laminating apparatus, such that corresponding portions of the padbias the tabs of the filler blank into corresponding veneers 530 of theblank 500, which may cause the laminating film to flow into the indicia540 of the veneers 530. The locating nest may be configured to generateand/or transfer heat at one or more locations along the inner surface.

The locating nest may define one or more alignment features that mayallow the filler blank, the adhesive release layer, and/or the blank 500to be properly located during an example indicia filling process. Forexample, the locating nest may define one or more posts that extendupward from the inner surface of the body along a direction that isperpendicular to the inner surface. Each post may be configured toreceive one or more of a corresponding aperture in the support strip ofthe filler blank, a corresponding aperture in the adhesive releaselayer, or an aperture 506 or 508 of a blank 500. The posts may beconfigured to facilitate proper orientation and alignment of the fillerblank, the adhesive release layer, and a blank 500 relative to eachother, and relative to the pad, during an indicia filling process.

The locating nest may define a groove that extends into the body along aportion of the outer perimeter of the body. The groove may be configuredto facilitate removal of the filler blank, the adhesive release layer,and a blank 500 at the conclusion of an indicia filling process. Thefiller blank, the adhesive release layer, and the blank 500 may bereferred to as a laminating assembly, for instance when disposed in thelaminating apparatus. The groove may be configured such that a portionof the filler blank and/or adhesive release layer extends into thegroove when the laminating assembly is properly oriented in the locatingnest. In an example, the groove may be sized to accommodate a fingerand/or thumb of an individual.

In accordance with an example implementation of a laminating apparatus,the pressure plate may include a substantially plate-shaped body thatdefines a downward-facing inner surface. The body of the pressure platemay define a rectangular outer perimeter that is substantially the sameas that of the locating nest. Stated differently, the inner surface ofthe pressure plate may define an area that is substantially the same asan area defined by the inner surface of the locating nest. The pressureplate may define one or more openings that extend into the innersurface. The openings may be configured to receive respective ones ofthe posts of the locating nest as the pressure plate and the locatingnest move toward each other during an indicia filling process. Thepressure plate may be configured to generate and/or transfer heat at oneor more locations along the inner surface.

One or both of the locating nest and the pressure plate may beconfigured such that laminating film of the filler blank that comes intocontact with respective surfaces of the locating nest and/or thepressure plate during an indicia filling process will not adhere toand/or accumulate on those surfaces. One or both of the locating nestand the pressure plate may be configured such that portions of the blank500 (e.g., the veneers 530) that come into contact with respectivesurfaces of the locating nest and/or the pressure plate during anindicia filling process will not adhere to those surfaces. It should beappreciated that the laminating apparatus is not limited to thelaminating press as described herein. For example, an alternativeimplementation of an indicia filling process may utilize a locating“sandwich” and a heated roller laminator.

In an example indicia filling process using laminating film, thelaminating apparatus may be prepared before the process is initiated.For example, preparation of the laminating apparatus may include placinga first release film on the pad in the locating nest and a secondrelease film on the inner surface of the pressure plate. The firstrelease film may be dimensioned such that an outer perimeter of thefirst release film conforms to an outer perimeter of the pad, or may beotherwise dimensioned. The second release film may be dimensioned suchthat an outer perimeter of the second release film conforms to an outerperimeter of the inner surface of the pressure plate, or may beotherwise dimensioned.

In a first step of the example indicia process, the filler blank, theadhesive release layer, and the blank 500 may be positioned on thelocating nest, so as to define a laminating assembly. The filler blank,the adhesive release layer, and the blank 500 may be disposed onto thelocating nest such that one or more posts of the locating nest arereceived in corresponding apertures of the filler blank, the adhesiverelease layer, and the blank 500, which may ensure proper orientation ofthe filler blank, the adhesive release layer, and the blank 500 relativeto each other. The filler blank may be disposed onto the locating nestsuch that the polyester side faces the inner surface of the locatingnest, and rests against the first release film and the pad, with the EVAside facing upward toward the inner surface of the pressure plate. Inthis regard, the polyester side of the filler blank may be referred toas a back side relative to the veneers 530, and the EVA side of thefiller blank may be referred to as a front side relative to the veneers530. The adhesive release layer may be placed on the filler blank, suchthat it rests on the EVA side of the filler blank. The blank 500 maythen be disposed onto the adhesive release layer and filler blank, withthe rear surface 504 of the blank 500 facing the inner surface of thelocating nest and the front surface 502 of the blank facing the innersurface of the pressure plate. It should be appreciated that theorientation of the laminating assembly relative to the laminatingapparatus is not limited to the example orientation described herein.For instance, the laminating assembly may be alternatively oriented inthe laminating apparatus, such as in an inverted or rotated orientationrelative to the orientation described herein.

In a second step of the example indicia filling process, with thelaminating assembly positioned on the locating nest, a heat and pressurecycle of the laminating apparatus may be initiated. The heat andpressure cycle may be performed for a predetermined amount of time. Inaccordance with an example heat and pressure cycle, the pressure platemay be configured to apply a controlled sequence of pressure and heat tothe laminating assembly. As heat and pressure are applied to the fillerblank, the adhesive release layer, and the blank 500, the laminatingfilm of the filler blank may flow into the respective indicia 540 of theveneers 530. The laminating film may bond with one or more surfaces ofthe veneers 530. For example, the laminating film may adhere to theinner surfaces of the indicia 540 and/or to the rear surfaces 535 of theveneers 530. The pressure plate may be configured to, at the end of thecontrolled sequence, back off and/or remove heat and pressure from thelaminating assembly such that the bond between the laminating film andthe veneers 530 is maintained. It should be appreciated that the exampleindicia filling process is not limited to the heat and pressure cycle asdescribed herein. For instance, the laminating apparatus mayalternatively be configured such that heat may be applied to thelaminating assembly by the pressure plate but not by the locating nest,or may be applied to the laminating assembly by both the pressure plateand the locating nest.

In a third step of the example indicia filling process, the finishedlaminating assembly may be removed from the laminating apparatus. Thefinished laminating assembly may be cooled, for instance actively and/orpassively, to allow the laminating film to cure before the laminatingassembly is removed from the laminating apparatus. The finishedlaminating assembly may be actively cooled, for example, during a timedcooling cycle performed using a solenoid-controlled air jet.Alternatively, the finished laminating assembly may be allowed topassively cool for a period of time before removal from the laminatingapparatus. In an example of removing the laminating assembly, anindividual may insert a finger and thumb into the groove, may pinchexposed portions of the filler blank and/or the adhesive release layer,and may remove the finished laminating assembly from the laminatingapparatus, for example by lifting the finished laminating assembly awayfrom the inner surface of the locating nest.

In a fourth step, with the finished laminating assembly removed from thelaminating apparatus, excess laminating film and/or adhesive releasematerial may be removed from the finished laminating assembly. Forexample, excess laminating film and/or adhesive release material may bepulled from the veneers 530. The excess material may be removed whilethe veneers 530 are attached to the blank 500 or after the veneers 530have been detached from the blank 500.

In another example implementation, the filler material may backfilledinto the indicia 540 without the application of heat. The fillermaterial may be any suitable material, such as ultraviolet (UV) curableacrylic adhesive. In accordance with an example of backfilling theindicia 540, the blank 500 may be placed, front surface 502 facingdownward, on a flat surface. The filler material may then be disposedinto the indicia 540 along the rear surfaces 535 of the veneers 530. Forexample, the acrylic adhesive may be mechanically disposed (e.g.,pressed) into the indicia 540.

The filler material may at least partially fill the indicia 540. Forexample, the filler material may fill the indicia 540 such that thefiller material defines a filler surface that may be subsurface orconvex relative to the front surfaces 533 of veneers 530. In such anexample, the filler surface may define one or more fillets along edgesof the inner surfaces of the indicia 540, which may reduce the effectivedepth of the indicia 540. Alternatively, the filler material may fillthe indicia 540 such that at least a portion of a filler surface definedby the filler material is substantially flush with (e.g., coplanar with)the front surfaces 533 of veneers 530.

Once disposed into the indicia 540, the acrylic adhesive may be cured,which may cause the acrylic adhesive to bond to the veneers 530, forinstance to inner surfaces of the indicia 540 and/or to the rearsurfaces 535 of the veneers 530. Optionally, the rear surface 535 ofeach veneer 530 may be wiped, for instance to remove excess fillermaterial. It should be appreciated that disposing the filler materialinto the indicia 540 is not limited to a backfilling process asdescribed herein, and that the filler material may otherwise be disposedinto the indicia 540. For example, the filler material may alternativelybe disposed into the indicia 540 along the front surfaces 533 of theveneers 530. Such a front surface 533 application may be performedwithout wiping filler material from the veneers 530.

Returning now to the example process 400, at 412, the veneers 530 may beseparated from the blank 500. For example, each veneer 530 may be freedby causing the tabs 509 to break, thereby releasing the veneer 530 fromthe blank 500. It should be appreciated that any portions of the tabs509 that remain attached to the veneers 530 after separation of theveneers 530 from the blank 500 may be too small to see with the nakedeye or to feel, such that a secondary cleaning process may not beperformed on the veneers 530 after separation from the blank 500.

At 414, assembly of the buttons 510 may be completed by securing eachveneer 530 to a corresponding button body 520 (e.g., as shown in FIGS.8A-8B). The button body 520 of each button 510 may be referred to as acarrier portion, such as a carrier portion of the button 510 or moregenerally as a carrier portion of a control device in which the button510 is installed, such as the keypad 100. Each button body 520 may havea front wall 522 that defines a front surface 523 and an opposed rearsurface 525 of the of the button body 520. The front wall 522 of eachbutton body 520 may be referred to as an outer surface of the button510. Each button body 520 may further include perimeter walls 524 thatextend rearward from the front wall 522. The perimeter walls 524 maydefine an outer perimeter that is slightly longer than that of the frontwall 522, such that each button body 520 defines a shallow shelf 526that extends around the perimeter of the front wall 522, such that thefront wall 522 defines a projection relative to the perimeter walls 524.

The plate portion 532 and peripheral walls 534 of each veneer 530 maydefine a cavity 538 that extends into a rear of the veneer 530. Thefront wall 522 of each button body 520 may be configured to be receivedin the cavity 538 of a corresponding one of the veneers 530, forinstance such that the peripheral walls 534 of the veneer 530 extend tothe perimeter walls 524 of the button body 520. In this regard, eachbutton body 520 may be configured such that the plate portion 532 andthe peripheral walls 534 of a corresponding veneer 530 at leastpartially enclose the front wall 522 of the button body 520 when theveneer 530 is attached to the button body 520. When each veneer 530 issecured in place relative to a corresponding button body 520, the rearsurface 535 of the plate portion 532 may abut the front surface 523 ofthe button body 520. The veneers 530 may be secured to correspondingbutton bodies 520 using an adhesive, for example. It should beappreciated that the veneers 530 may be otherwise secured to thecorresponding button bodies 520, for example via mechanical attachment,such as tabs, snap locks, fasteners, or the like.

The button bodies 520 may be made of a translucent material, forinstance white or clear plastic, such that when the button bodies 520are backlit, light may pass through the button bodies 520 and reach therear surfaces 535 of the plate portions 532 of the veneers 530. Suchlight may be emitted, for example, from the interior of a control devicein which the buttons 510 are installed. In accordance with such animplementation, the indicia 540 of the veneers 530 may exposecorresponding underlying surfaces of the button bodies 520, such thatthe indicia 540 may be illuminated when the button bodies 520 arebacklit. In this regard, the veneers 530 may be configured to be securedto the backlit buttons of a control device.

It should be appreciated that the example process 400 is not limited tothe illustrated operations 402-414. For example, one or more operationsof the example process 400 may be omitted. To illustrate, in analternative example process the formation of the blank 500, at 402, maybe omitted. However, the remaining portions of the process 400 may beperformed on the unformed blank 500. It should further be appreciatedthat the example process 400 is not limited to the illustrated order ofperforming the operations. For example, the veneers 530 may be separatedfrom the blank 500 before the filler material is disposed into theindicia 540, such that 412 may alternatively be performed before 410.

It should be appreciated that the example processes and manufacturingtechniques illustrated and described herein are not limited to theproduction of laser-cut veneers for application to the buttons ofbacklit keypads, and that those example processes and manufacturingtechniques may be otherwise applied, for instance to laser cutting othercomponents of a control device.

For example, FIG. 9 depicts an example control device that may beconfigured to operate in a load control system for controlling one ormore load control devices and/or electrical loads, such as lightingloads, motorized window treatments, or the like. As shown, the exampleload control device is configured as a wall-mounted keypad 600. Thekeypad 600 may include a faceplate 602, one or more buttons 610, and ahousing 620 that is configured to be mounted to a structure, such aswithin a wallbox that is installed in an interior wall of a building.The faceplate 602 may define an opening 604 that extends therethroughand that is configured to at least partially receive the buttons 610 anda bezel 614 that carries the buttons 610. The illustrated keypad 600 maybe configured to control a load control device, such as a load controldevice configured to control an amount of power delivered to one or moreelectrical loads (e.g., one or more lighting loads) from a power source,such as an alternating-current (AC) power source or a direct current(DC) power source.

The faceplate 602 may include a faceplate body (not shown) and a veneer630 that is attached to a front surface of the faceplate body. Thefaceplate body may be referred to as a carrier portion, such as acarrier portion of the faceplate 602 or more generally as a carrierportion of the keypad 600. The veneer 630 of the faceplate 602 mayinclude a plate portion 632 and peripheral walls 634 that extend arounda perimeter of the veneer 630. The plate portion 632 may define a frontsurface 633 of the veneer 630, and more generally a front surface of thefaceplate 602. As shown, the plate portion 632 may define a flat,substantially planar front surface 633. The veneer 630 may be made ofany suitable material, such as metal. The veneer 630 may be made ofsheet metal, for example, and the plate portion 632 and the peripheralwalls 634 may be defined, for example by an embossing process, aprogressive stamping process, or the like.

The plate portion 632 and peripheral walls 634 of the veneer 630 maydefine a cavity 638 that extends into a rear of the veneer 630. Thefaceplate body may be configured to be received in the cavity 638 of theveneers 630. The veneer 630 may be secured to the faceplate body usingan adhesive, for example. It should be appreciated that the veneer 630may be otherwise secured to the faceplate body, for example viamechanical attachment, such as tabs, snap locks, fasteners, or the like.

The veneer 630 may include one or more indicia, such as indicia 640 thatare defined in the plate portion 632 of the veneer 630. In accordancewith the faceplate 602 of the illustrated keypad 600, the indicia 640may be words that are indicative of respective functions that may beperformed by the keypad 600, and that may be invoked by depressing thebuttons 610. The indicia 640 may be laser cut through the veneer 630.For example, the indicia 640 may be formed during a laser cuttingprocess. Forming the indicia 640 of the veneer 630 via a laser cuttingprocess may enable the indicia 640 to exhibit one or morecharacteristics that are not typically achievable in indicia defined viaknown processes of button veneer manufacture, such as machining.Examples of such characteristics are illustrated in FIGS. 2 and 3 anddescribed herein.

The keypad 600 may include one or more lighting elements (not shown)that are configured to illuminate the indicia 640 from within theinterior of the keypad 600, such that the indicia 640 are backlit. Forexample, the keypad 600 may include a plurality of lighting elements,such as light emitting diodes (LEDs), that are disposed within thehousing 620 of the keypad 600, behind the faceplate 602, and that areconfigured to backlight the faceplate 602. In this regard, theillustrated keypad 600 may be referred to as a backlit keypad or controldevice.

As shown, the indicia 640 extend into the front surface 633 of theveneer 630 and through the plate portion 632. The front surface 633 ofthe veneer 230 may alternatively be referred to as an outer surface ofthe veneer 630, and more generally as an outer surface of the faceplate602. The faceplate body may be made of a translucent material, forinstance white or clear plastic, such that when the faceplate body isbacklit, light may pass through the faceplate body and reach an innersurface of the veneer 630, for example an inner surface of the plateportion 632. Such light may be emitted, for example, from the interiorof the keypad 600. In accordance with such an implementation, theindicia 640 of the veneer 630 may expose corresponding underlyingsurfaces of the faceplate body, such that the indicia 640 may beilluminated when the faceplate body is backlit. In this regard, theveneer 630 may be configured to be secured to a backlit faceplate of acontrol device.

The illustrated indicia 640 include letters that form respective words.However, the indicia 640 are not limited to letters, and may include anycombination of alphanumeric characters, icons (e.g., symbols), or thelike. The indicia 640 may be representative of a command for controllingan electrical load. For example, the indicia 640 may be representativeof: a command message that may be transmitted by the keypad 600; of acommand that is executed internally by the keypad 600; of a result ofthe performance of a command; or the like. To illustrate, the indicia640 may be representative of predetermined scenes that correspond torespective lighting intensities of one or more lighting loads that arecontrolled by the keypad 600. One or more command messages to invoke acorresponding scene may be transmitted by the keypad 600 in response toone or more actuations of the buttons 610, for example.

The veneer 630 may include a filler material (not shown) that isdisposed into the indicia 640. The filler material may, for example, bebackfilled into the indicia 640 such that the filler material iscoplanar with the front surface 633 of the veneer 630. The fillermaterial may, for example, function to improve the optical performanceof the indicia 640 when one or more of the buttons 610 are backlit, forinstance to improve the readability of the indicia 640 when viewed fromoff angle.

The invention claimed is:
 1. A veneer that is configured to be securedto a backlit button of a control device, the veneer comprising: a plateportion that includes one or more indicia defined therethrough by alaser cutting process, wherein at least one of the one or more indiciacomprises an alphanumeric character, and wherein the plate portiondefines a rib that suspends a floating portion of the alphanumericcharacter relative to an open portion of the alphanumeric character,wherein the rib defines a thickness that does not exceed 0.003 inches.2. The veneer of claim 1, wherein at least a section of the alphanumericcharacter defines a variable line width.
 3. The veneer of claim 1,wherein the one or more indicia comprises a plurality of alphanumericcharacters that are representative of a command for controlling anelectrical load.
 4. The veneer of claim 1, wherein at least one of theone or more indicia comprises an icon that is representative of acommand for controlling an electrical load.
 5. The veneer of claim 1,wherein at least one of the one or more indicia defines a zero-radiuscorner.
 6. The veneer of claim 1, wherein the one or more indicia defineinner surfaces that are substantially perpendicular to an outer surfaceof the plate portion.
 7. The veneer of claim 1, wherein the plateportion further includes rounded corners, the rounded corners defined bythe laser cutting process.
 8. The veneer of claim 1, further comprisinga filler material that is disposed in the one or more indicia.
 9. Theveneer of claim 8, wherein the filler material comprises a laminatingfilm that is heated and pressed into the one or more indicia.
 10. Theveneer of claim 9, wherein the laminating film is applied to aninward-facing surface of the plate portion.
 11. The veneer of claim 8,wherein the filler material comprises a curable acrylic adhesive that ispressed into the one or more indicia.
 12. The veneer of claim 11,wherein the acrylic adhesive is applied to an inward-facing surface ofthe plate portion.
 13. A veneer that is configured to be secured to abacklit button of a control device, the veneer comprising: a plateportion that includes one or more indicia defined therethrough by alaser cutting process; and, wherein the plate portion further includesouter edges that extend along an outer perimeter of the plate portionand that are angularly offset relative to a front surface of the veneer;wherein at least one of the one or more indicia comprises analphanumeric character; and wherein the plate portion defines a rib thatsuspends a floating portion of the alphanumeric character relative to anopen portion of the alphanumeric character; and wherein the rib definesa thickness that does not exceed 0.003 inches.
 14. The veneer of claim13, wherein the plate portion of the veneer is configured to bepartially cut-out via one or more laser cuts along the outer edges. 15.The veneer of claim 14, wherein the plate portion comprises a surfacefinish, the surface finish configured to be formed before the plateportion of the veneer is partially cut-out.
 16. A control device that isconfigured for use with a load control device, the load control deviceconfigured to control an amount of power delivered to an electrical loadfrom a power source, the control device comprising: a carrier portionthat defines an outer surface and an opposed inner surface; a veneerthat is attached to the outer surface of the carrier portion, the veneerincluding one or more laser-cut indicia that extend therethrough; and atleast one lighting element that is configured to illuminate the innersurface of the carrier portion, wherein at least one of the one or morelaser-cut indicia is representative of a command for controlling theamount of power delivered to the electrical load, wherein at least oneof the one or more laser-cut indicia comprises an alphanumericcharacter, and wherein the veneer defines a rib that suspends a floatingportion of the alphanumeric character relative to an open portion of thealphanumeric character, and wherein the rib defines a thickness thatdoes not exceed 0.003 inches.
 17. The control device of claim 16,wherein at least a section of the alphanumeric character defines avariable line width.
 18. The control device of claim 16, wherein the atleast one of the one or more laser-cut indicia comprises one or morealphanumeric characters that are representative of a command that thecontrol device is configured to transmit to the load control device tocontrol the amount of power delivered to the electrical load.
 19. Thecontrol device of claim 16, wherein at least one of the one or morelaser-cut indicia comprises an icon that is representative of a commandthat the control device is configured to transmit to the load controldevice to control the amount of power delivered to the electrical load.20. The control device of claim 16, wherein at least one of the one ormore laser-cut indicia defines a zero-radius corner.
 21. The controldevice of claim 16, wherein the one or more laser-cut indicia definerespective inner surfaces that are substantially perpendicular to theouter surface of the carrier portion.
 22. The control device of claim16, wherein the veneer defines laser-cut rounded corners.
 23. Thecontrol device of claim 16, wherein the carrier portion comprises abutton body.
 24. The control device of claim 16, wherein the carrierportion comprises a faceplate body.
 25. The control device of claim 16,further comprising a second veneer, wherein the veneers of the controldevice are configured to be partially cut-out from a same embossed sheetmetal blank via one or more laser cuts.
 26. The control device of claim25, wherein the veneers of the same embossed sheet metal blank each havea surface finish, wherein the surface finish is the same for each veneerof the control device.
 27. The control device of claim 25, wherein theone or more laser-cut indicia of the veneer is configured to belaser-cut by a laser at a first focal point along a vertical direction,and wherein partially cut-out veneers from the same embossed sheet areconfigured to be laser-cut by the laser at a second focal point alongthe vertical direction.
 28. A control device that is configured for usewith a load control device, the load control device configured tocontrol an amount of power delivered to an electrical load from a powersource, the control device comprising: a carrier portion that defines anouter surface and an opposed inner surface; at least one lightingelement that is configured to illuminate the inner surface of thecarrier portion; and a veneer that is attached to the outer surface ofthe carrier portion, the veneer including one or more laser-cut indiciathat extend therethrough, wherein at least one of the one or morelaser-cut indicia comprises an alphanumeric character; wherein theveneer defines a rib that suspends a floating portion of thealphanumeric character relative to an open portion of the alphanumericcharacter, and wherein the rib defines a thickness that does not exceed0.003 inches.